Single valve ready to use hose end sprayer

ABSTRACT

Disclosed herein are various embodiments related to a chemical sprayer that includes a sprayer head assembly and a container. The container defines a cavity for storing a chemical to be sprayed. The sprayer head assembly includes a chemical passage, a carrier fluid passage, a vent passage, a valve chamber and a valve. The chemical passage is communication with the cavity. The carrier fluid passage is in communication with a carrier fluid source. Both the carrier fluid and chemical passages are in communication with the valve chamber. The valve is moveably positioned within the valve chamber and defines at least partially a first passage and a second passage. The first passage is configured so as to be in communication with the chemical passage when the valve is in an open position. The second passage is configured so as to be in communication with the carrier fluid passage when the valve is in the open position. In one embodiment, the assembly also includes a sealing member that may be biased in one direction and actuated to open and close the vent passage.

RELATED APPLICATIONS

This application claims priority pursuant to 35 U.S.C. 119(e) toco-pending U.S. Provisional Patent Application Ser. No. 60/546,380,filed Feb. 20, 2004, which is hereby incorporated by reference in itsentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments disclosed herein relate to chemical dispensing sprayers and,in particular, to aspiration-type sprayers that use a relatively largeamount of carrier fluid for dispensing a relatively small amount of achemical solution.

2. Description of the Related Art

Every year consumers apply thousands of gallons of chemicals such asfertilizers or pesticides to plants, lawns, flowers, vegetable gardensand other organic type vegetation. Typically, such chemicals are sold inplastic containers in a concentrated form. While in this concentratedform, the chemical is extremely hazardous to the consumer end user andthe environment in general. Accordingly, the container typicallyincludes an aspiration-type sprayer head assembly. An aspiration-typesprayer uses a relatively large amount of carrier fluid, such as water,to withdraw, dilute and dispense a relatively small amount of chemicalfrom the container. To further prevent harm to the consumer, thecontainer and the sprayer head assembly are preferably disposed of afterthe container's contents are exhausted. It is therefore desirable toprovide a sprayer head assembly that is sufficiently low cost so as toallow the entire unit to be discarded and yet reliable and safe.

SUMMARY OF THE INVENTION

Therefore in a preferred embodiment of the invention, there is provideda safe and reliable aspiration type chemical sprayer that utilizes aminimum number of components and that is relatively easy to manufactureand assemble.

Accordingly, one aspect of a preferred embodiment involves a chemicalsprayer that comprises a sprayer head assembly and a container. Thecontainer defines a cavity for storing a chemical to be sprayed. Thesprayer head assembly includes a chemical passage, a carrier fluidpassage, a valve chamber and a valve. The chemical passage is incommunication with the cavity. The carrier fluid passage is incommunication with a carrier fluid source. Both the carrier fluid andchemical passages are in communication with the valve chamber. The valveis moveably positioned within the valve chamber and defines at leastpartially a first passage and a second passage. The first passage isconfigured so as to be in communication with the chemical passage whenthe valve is in an open position. The second passage is configured so asto be in communication with the carrier fluid passage when the valve isin the open position. The first and second passages are also configuredso as to not be in communication with the chemical and carrier fluidpassages when said valve is in a closed position. The valve alsoincludes one or more seal portions positioned on the valve so as toblock both the chemical and the carrier fluid passages when said valveis in the closed position.

Another aspect of a preferred embodiment involves a chemical sprayercomprising a sprayer head assembly and a container. The containerdefines a cavity for storing a chemical to be sprayed. The sprayer headassembly includes a chemical passage that is in communication with thecavity. The assembly also includes a carrier fluid passage that is incommunication with a carrier fluid source. The assembly further includesa valve and a valve chamber. The valve chamber is in communication withthe chemical and carrier fluid passages. The valve is moveablypositioned within the valve chamber. The valve defines at least in parta first passage that is in communication with the chemical passage whenthe valve is in an open position. The valve also defines at least inpart a second passage that is in communication with the carrier fluidpassage when the valve is in the open position. The valve also includesa suction generating surface. The first passage has a mouth at thesuction generating surface. The suction generating surface is positionedand configured such that the flow of carrier fluid over the suctiongenerating surface creates a suction that draws chemical through thechemical passage to the mouth.

Yet, another aspect of a preferred embodiment involves a chemicalsprayer comprising a sprayer head assembly and a container. Thecontainer defines a cavity for storing a chemical to be sprayed. Thesprayer head assembly includes a chemical passage, a carrier fluidpassage, a valve chamber, a valve, and an outlet. The chemical passageis in communication with the cavity. The carrier fluid passage is incommunication with a carrier fluid source. The valve chamber is incommunication with the chemical and carrier fluid passages. The valve ismoveably positioned within the valve chamber. The valve defines at leastin part a first passage that communicates with the chemical passage whenthe valve is in an open position. The chemical passage terminates at asuction generating surface that is defined by the valve. The suctiongenerating surface is positioned and configured such that the flow ofcarrier fluid over the suction generating surface creates a suction thatdraws chemical through the chemical passage to the suction generatingsurface. The outlet for the carrier fluid and the chemical is formed atleast in part by the valve.

Yet another embodiment involves a chemical sprayer comprising a sprayerhead assembly and a container. The container defines a cavity forstoring a chemical to be sprayed. The sprayer head assembly comprises achemical passage that is in communication with the cavity and a carrierfluid passage that is in communication with a carrier fluid source. Avalve chamber is in communication with the chemical passage. A valve ismoveably positioned within the valve chamber. The valve defines at leastin part a first passage that communicates with the chemical passage whenthe valve is in an open position. The valve also defines a meteringorifice that is in communication with the first passage.

Another embodiment involves a chemical sprayer comprising a sprayer headassembly and a container. The container defines a cavity for storing achemical to be sprayed. The sprayer head assembly comprises a chemicalpassage that is in communication with the cavity. A carrier fluidpassage is in communication with a carrier fluid source. A valve chamberis in communication with the chemical passage. A valve is moveablypositioned within the valve chamber. The valve may define at least inpart a first passage that is in communication with the chemical passagewhen the valve is in an open position. The valve further includes one ormore sealing portions that form an annular seal around the chemicalpassage when the valve is in the open position. In yet anotherembodiment, the assembly may also include a sealing member that may bebiased in one direction and actuated to open and close the vent passage.

All of these embodiments are intended to be within the scope of theinvention herein disclosed. These and other embodiments of the presentinvention will become readily apparent to those skilled in the art fromthe following detailed description of the preferred embodiments havingreference to the attached figures, the invention not being limited toany particular preferred embodiment(s) disclosed.

For purposes of summarizing the invention and the advantages achievedover the prior art, certain objects and advantages of the invention havebeen described herein above. Of course, it is to be understood that notnecessarily all such objects or advantages may be achieved in accordancewith any particular embodiment of the invention. Thus, for example,those skilled in the art will recognize that the invention may beembodied or carried out in a manner that achieves or optimizes oneadvantage or group of advantages as taught herein without necessarilyachieving other objects or advantages as may be taught or suggestedherein.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will now be described withreference to the drawings of the preferred embodiments, which areintended to illustrate and not to limit the invention, and in which:

FIG. 1 is a perspective view sprayer head assembly that is attached to achemical container; the sprayer head assembly having certain featuresand advantages that are in accordance with the principles of the presentinvention;

FIG. 2 is side view of the sprayer head assembly of FIG. 1 in a closedposition;

FIG. 3 is side view of the sprayer head assembly of FIG. 1 in an openposition;

FIG. 4 is a top view of the sprayer head assembly of FIG. 1;

FIG. 5 is a bottom view of the sprayer head assembly of FIG. 1;

FIG. 6 is a cross-sectional view of the sprayer head assembly in theclosed position taken along line 6-6 of FIG. 4;

FIG. 6A is an enlarged view of a portion of the sprayer head assembly ofFIG. 6;

FIG. 7 is a cross-sectional view of the sprayer head assembly in theopen position taken along line 7-7 of FIG. 4;

FIG. 7A is an enlarged view of a portion of the sprayer head assembly ofFIG. 7;

FIG. 8 is another side view of a different side of the sprayer headassembly of FIG. 2;

FIG. 9 is a front view of the sprayer head assembly of FIG. 1;

FIG. 10A is a perspective of the control valve having certain featuresand advantages according to the present invention;

FIG. 10B is an side view of the control valve of FIG. 10A;

FIG. 10C is another side view from a different side of the control valveof FIG. 10A;

FIG. 10D is a bottom view of the control valve of FIG. 10A;

FIG. 11A is a side view of a sealing member having certain features andadvantages according to the present invention;

FIG. 11B is a front view of the sealing member of FIG. 11A

FIG. 11C is a rear view of the sealing member of FIG. 11A;

FIG. 12A is a cross-sectional view taken along line 12A-12B12A-12A ofFIG. 11B;

FIG. 12B is a cross-sectional view taken along line 12B-12B of FIG. 11B;

FIG. 13A is a cross-sectional view of a modified embodiment of a sprayerhead in a closed position taken through the housing and the valve alonga plane generally perpendicular to a longitudinal axis of the valve;

FIG. 13B is a cross-sectional view as in FIG. 13A wherein the valve isin an open position;

FIG. 14A is a cross-sectional view taken through line A-A of FIG. 13A;

FIG. 14B is a cross-sectional view taken through line B-B of FIG. 13B;

FIGS. 15A-C are top, side and bottom views of a vent seal pad of theassembly of FIG. 13A;

FIG. 16 is a top perspective cross-sectional view of the assembly ofFIG. 13A with the valve removed and to the side;

FIG. 17 is a side perspective view of the sprayer head of the assemblyof FIG. 13A with the valve removed;

FIG. 18 is a top cross-sectional view of the sprayer head of theassembly of FIG. 13A with the valve removed;

FIG. 19 is a side cross-sectional view of the assembly of FIG. 13A in anopen position; and

FIG. 20 is close up view of a rear portion of the assembly of FIG. 13A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A sprayer head assembly 10 according a preferred embodiment of thepresent invention is illustrated in FIGS. 1-12B. As shown in FIG. 1, thesprayer head assembly 10 is connected to a chemical container 12. Thesprayer head assembly 10 includes a sprayer head 14, a containerconnection portion 16, a supply fluid connection portion 18, and arotatable control valve 20. The sprayer head assembly 10 may be made ofany suitable material that is resistant to and compatible with thechemical fluid to be sprayed. However, a flexible plastic material, suchas polypropylene, is preferred because it is resilient yet durable.

With reference to FIGS. 1 and 6, the valve 20 is moveably positioned ina cylindrical bore 22 that is formed in the sprayer head 14 of thesprayer head assembly 10. The valve includes a gripping area or handle24 that is mounted onto a valve cap 21. An operator opens and closes thevalve 20 by twisting the handle 24. The valve 20, bore 22, and handle 24are illustrated as being arranged substantially about a horizontal axis.This horizontal arrangement of the valve 20, bore 22, and handle 24 ispreferred because it allows the operator to rotate the valve 20 in anergonomical position. That is, the operator can hold the container 12 inone hand and rotate the valve 20 with the other hand without excessiverotation and lifting of the elbows and shoulders. In comparison, if thevalve 20 is arranged in a vertical position, the operator typically hasto lift and twist the operator's shoulders and elbows in order to rotatea valve 20. However, those of ordinary skill in the art will recognizethat many of the aspects of the present invention may be achieved withthe valve 20 arranged along a non-horizontal axis. The construction thevalve 20 and bore 22 will be described in more detail below.

With continued reference to FIGS. 1 and 6, the connection between thesprayer head assembly 10 and the container can be achieved by providingthe container connection portion 16 with a conventional rotatablecoupler 26 and a washer 28. The rotatable coupler 26 includes internalthreads 30 that cooperate with corresponding threads (not shown) formedon the neck of the container 12.

The sprayer head assembly 10 can also be permanently attached to thecontainer 12. In such an arrangement, adhesive can be applied to theinner surface of the connection portion 16 before it is fitted over theneck of the container 12. Alternatively, the connection portion 16 caninclude an inwardly projecting ratchet that opposes a cooperatingratchet formed on the container 12.

When the sprayer head assembly 10 is installed onto the container 12,the interior of the container 12 is in communication with a chemicalpassage 32 that is also in communication with the interior of thecylindrical bore 22. In the illustrated arrangement, the chemicalpassage 32 is defined in part by a downwardly depending chemical flowtube or dip tube 34. The dip tube 34 extends into the container 12 andpreferably terminates near a bottom surface of the container. Thechemical passage 32 is also defined in part by an internal passage 38,which is formed in the sprayer head 14. The internal passage 38communicates with the interior of the cylindrical bore 22 and the diptube 34. The dip tube 34 is secured in fluid communication with theinternal passage 38 by a cylindrical boss 36. Although, in theillustrated arrangement the chemical passage 32 is defined by twocomponents (the dip tube 34 and the internal passage 38), it should beappreciated that the chemical passage 32 can be defined by a singlecomponent or more than two components. The illustrated arrangement,however, is preferred because it is easy to manufacture and yet uses asmall number of components.

Preferably, the sprayer head assembly 10 includes a vent passage 52,which is shown in FIG. 5. In the illustrated arrangement, the ventpassage 52 is defined by a small hole formed in the head 14 of theassembly. As with the chemical passage 32, the vent passage 52communicates with the interior of the container 12 when the assembly 10is mounted onto the container 12. The vent passage 52 extends up throughhead 14 and communicates with the interior of the cylindrical bore 22.The vent passage 52 lies generally parallel to (and spaced along theaxis of the valve from) the interior passage 32. Although, in theillustrated arrangement the vent passage 52 is formed on the assembly10, it should be appreciated that the vent passage 52 can be located onthe container 12. However, the illustrated arrangement is preferredbecause, as will be explained below, it enables the vent passage 52 tobe opened and closed with the chemical passage 32.

As mentioned above, the sprayer head assembly 10 also includes a supplyfluid connection portion 18 (see FIG. 6). The supply fluid connectionportion 18 connects the assembly to a pressurized supply fluid source(not shown), such as, for example, a garden hose. In the illustratedarrangement, the connection is formed by a conventional rotatablecoupler 40 and a washer 42. The coupler 40 includes threads 44 thatcooperate with corresponding threads (not shown) formed on the supplyfluid source. One of ordinary skill in the art will appreciate thatother means can be used to connect the assembly 10 to the supply fluidsource.

With continued reference to FIG. 6, the sprayer head assembly 10includes a supply passage 46. The supply passage 46 is in communicationwith the supply fluid source and the interior of the bore 22. In theillustrated arrangement, the supply passage 46 is defined in part by aside wall 48 of the sprayer head 14. The side wall 48 extends from thecoupler 40 towards the cylindrical bore 22. The supply passage 46 isalso defined in part by an elongated constriction passage 50, which inthe preferred embodiment directly communicates with the cylindrical bore22. The elongated constriction passage 50 helps to produce a uniform,non-turbulent stream of carrier fluid into the bore 22. In theillustrated arrangement, the side wall 48 and the elongated constrictionpassage 50 are integrated together. However, it should be appreciatedthat these components can be made separately. It should also beappreciated that the supply passage 46 can be defined by a singlecomponent or more than two components, which can be integrated togetheror made separately. The illustrated arrangement is preferred because itis relatively simple to form and produces the desired uniform stream ofcarrier fluid.

As best seen in FIGS. 10A-D, the valve 20 is constructed with two outerwalls 54 that define a cylindrical periphery for sliding engagement withthe interior wall of the cylindrical bore 22 (FIG. 6). Preferably, theouter wall 54 nearest the handle 24 engages an annular groove 51 (shownin dashed lines in FIG. 4) that is formed along the interior wall of thecylindrical bore 22. Accordingly, the valve 20 is inserted into thesprayer head 14 by snap-fitting the valve 20 into the annular groove 51.Once snap-fitted, the valve 20 can rotate within the cylindrical bore 22but is secured axially by the engagement of the outer wall 54 with theannular groove 51. The bore 22 is closed at one end by a bore cover 23(see FIG. 8) that is preferably integrated with the assembly head 14.The bore 22 is closed at the other end by the valve cap 21.

In order to reduce the amount of material used in the valve 20, thevalve 20 is preferably hollowed out. That is, several gaps 55 are formedin the body of the valve 20. These gaps 55 are positioned so as not tocompromise the structural integrity of the valve 20.

As will be explained below, the valve 20 controls the flow of chemicalthrough the assembly 10. The valve 20 also preferably controls the flowof supply fluid through the assembly 10. More preferably, the valve 20also controls the communication of the vent passage 52 with atmosphericpressure.

Accordingly, as best seen in FIG. 7, the valve 20 defines at least inpart a first passage 56. The first passage 56 is configured andpositioned within the valve 20 such that when the valve 20 is in an openposition (i.e., the position shown in FIG. 7) the first passage 56 isaligned with and communicates with the chemical passage 32. Preferably,the first passage 56 has a diameter that is slightly larger than thediameter of the internal passage 38. This arrangement helps to align thefirst passage 56 with the internal passage 38.

As best seen in FIG. 7A, the first passage 56 preferably communicateswith a generally cylindrical metering orifice 74 that terminates at agenerally cylindrical mouth 75. The mouth 75 is located within agraduated suction generating recess 76, which is formed on a surface 57.Preferably, the valve 20 defines the metering orifice 74, the mouth 75,the suction generating recess 76 and the surface 57. However, it shouldbe appreciated that several advantages of the present invention can beachieved in an arrangement where the metering orifice 74, the mouth 75,the suction generating recess 76 and/or the surface 57 are not definedby the valve 20. The illustrated arrangement is preferred because, aswill be explained in more detail below, the metering orifice 74 and themouth 75 can be more accurately manufactured.

The diameter of the metering orifice 74 may determine the dilution ratioof the sprayer head assembly 10. The method for determining the diameterof the metering orifice 74 to achieve a desired dilution ratio are wellknown to those of ordinary skill in the art; therefore, a detaileddescription of such a method is not necessary.

As best seen in FIG. 10B, the surface 57 defines the graduated suctiongenerating recess 76. The recess 76 has a generally triangular shapethat is formed by two side walls 77 and a rounded end wall 79. The mouth75 of the metering orifice lies on a lower face 81 of the recess 76 nearthe rounded end wall 89. The recess 76 is deepest at the apex where themouth 75 of the metering orifice 74 is located. The graduated suctiongenerating recess 76 is sized and configured, as is well known in theart, so that when carrier fluid flows over the 76 recess a suction forceis created. The suction force draws the chemical from the container 12through the chemical passage 32. Of course, one of ordinary skill in theart will recognize that the desired suction force can be created withgraduated suction generating recesses of other shapes and sizes.

As best seen in FIG. 7A, the valve 20 also defines, at least partially,a second passage 58 that is aligned with the supply passage 46 when thevalve 20 is in the open position. The second passage 58 is preferablydefined by the surface 57, the inner surface of the cylindrical bore 22,and a pair of side walls 60 (see FIG. 10B) that are defined by the valve20. It should also be appreciated that the second passage 58 can bedefined entirely by the valve 20. That is, interior surface of thecylindrical bore 22 can be replaced, wholly or in part, by an additionalwall of the valve 20. However, the illustrated arrangement is preferredfor several reasons. For example, this arrangement reduces the amount ofmaterial need to form the valve 20. In addition, the surface may beformed with out or with a modified recess 76 an increases ease ofmanufacturing.

With continued reference to FIG. 7A, the valve 20 includes a sealingportion 63 that forms an annular seal with the bore 22 around theinterface between the chemical passage 32 and the first passage 56.Accordingly, the connection between the chemical passage 32 and thefirst passage 56 is sealed and chemical is prevented from leaking intothe gaps between the valve 20 and the cylindrical bore 22.

The sealing portion 63 is preferably formed from a separate singlesealing member 64 (see also FIGS. 11 and 12) that is positioned within arecess 70 (see FIG. 10C) formed on the valve 20. The sealing member 64is preferably made of a soft plastic elastomer material or othersuitable synthetic rubber material. Such material provides an effectiveseal with the bore 22, which as mentioned above is preferably made of aharder plastic material. The sealing member 64 defines at least in parta transition passage 66, which defines part of the first passage 56.Accordingly, the transition passage 66 is in communication with thechemical passage 32 when the valve 20 is in the open position.

Because the sealing surface 63 is positioned on the valve 20, it is mucheasier to assemble the assembly 10 as compared to a sprayer where thesealing surfaces are located on the head 14. Such a sprayer isparticularly difficult to assemble because it is difficult to reach theinterior surfaces of the head. This arrangement also eliminates the needfor multiple O-rings on the valve.

Preferably, the sealing member 64 also preferably includes a channel orrecess 67 (see FIG. 12B) that at least partially surrounds the openingof the transition passage 66. This recess 67 helps to align thetransition 66 and chemical passages 32.

With reference to FIGS. 11B and 12A, the sealing member 64 alsopreferably includes a channel 68. When the valve is at the openposition, the channel 68 is aligned with the vent passage 52.Accordingly, the channel 68 allows the vent passage 52 to be incommunication with gaps that are formed between the valve 20 and thecylindrical bore 22. Accordingly, when the valve 20 is in the openposition, the vent passage 52 is in communication with an atmosphericpressure source.

As best seen in FIG. 6A, the sealing portion 63 is also preferablyarranged on the valve so as to block both the carrier fluid passage 46and the chemical fluid passage 32 when the valve 20 is in the closedposition. The sealing portion 63 also preferably blocks the vent passage52. Furthermore, as the valve 20 is rotated to the closed position (FIG.6) from an open position (FIG. 7) the sealing portion 63 of the valve 20is preferably positioned such that it remains in contact with the outletof the chemical passage 32. In a similar manner, the sealing portion 63also seals the vent passage 52 as the valve 20 is rotated to the closedposition.

The illustrated sealing portion 63 of the valve 20 is formed from asingle sealing member 64 that simultaneously blocks the carrier passage46, the chemical passage 32, and the vent passage 52 when the valve isin the closed position. This arrangement is preferred because it reducesthe number of parts required to construct the assembly 10. However, itshould be appreciated that the sealing portion 63 could be formed from aplurality of sealing members 64 positioned within one or more recessespositioned on the valve 20. It should also be appreciated that, althoughthe illustrated sealing portion 63 is preferably formed from a separatesealing member 64, the sealing portion 63 can be integrated into thevalve 20 such that the valve 20 and sealing portion 63 comprise a singleintegrated part.

In operation, when the valve 20 is in the open position (see FIG. 7A), astream of pressurized carrier fluid is discharged into the secondpassage 58. As the carrier fluid flows over the surface 57, a suctionforce is created that draws chemical through the dip tube 34, transitionpassage 66, and first passage 56 and into the stream of carrier fluid.The upwardly inclined orientation of the surface 57 helps to generatethe suction force. Venting is provided through the vent passage 52 (seeFIG. 5) and the channel 68 (see FIG. 11B).

Preferably, the chemical and carrier fluid is directly discharged fromthe assembly 10 through the second passage 58. Accordingly, in order toproduce an effective spray pattern, the channel walls 60 (see FIG. 10B)diverge slightly as they extend from the carrier passage 46. Thisconfiguration helps to spread the carrier fluid and chemical stream. Theupwardly inclined orientation of the surface 57 of the valve 20 alsohelps to direct the chemical and carrier fluid stream away from theuser.

As best seen in FIG. 7, the assembly 10 preferably includes a hood 19that extends from the head 14 and the second passage 58. It should beappreciated that the hood 19 is not necessary to practice the presentinvention. However, the hood 19 is preferred because it protects theoperator from water and chemical splatter. It should also be appreciatedthat an additional outlet nozzle could be added to the assembly 10 tofurther direct the water and chemical flow. Such a nozzle can extendfrom the second passage 58 and would offer additional control of thecarrier fluid and chemical stream. In such an arrangement, one ofordinary skill in the art will recognize that the channel walls 60 donot have to be divergent. The illustrated arrangement is preferred,however, because it reduces the size of the assembly 10 and the numberof components and yet still produces an effective spray pattern.

When the valve is rotated to the closed position (see FIG. 6A), thecarrier passage 46, chemical passage 32 and the vent passage 52 are allclosed by the valve 20. Specifically, the sealing portion 63 of thevalve 20 forms a tight seal over these passages and prevents leakage. Aparticular advantage of the illustrated arrangement is the manner inwhich the sealing portion 63 is supported on the valve 20. As seen inFIG. 6A, the sealing portion 63 is formed by the sealing member 64,which is supported in the recess 70. The recess 70 is formed in asubstantially cylindrical sealing wall 80 of the valve 20. In the closedposition, the sealing wall 80 extends across the carrier fluid passage46. Because the carrier fluid is pressurized, the carrier fluid exerts arelatively large force on the sealing member 64 and the sealing wall 80.This force pushes the sealing wall 80 away from the interior of thebore, which can cause the sealing wall 80 to flex. Flexing of thesealing wall 80 can compromise the seal between the sealing member 64and the carrier fluid passage 46. Accordingly, the valve 20 preferablyincludes a bracing wall 82. As seen in FIG. 6A, the bracing wall 82preferably extends across the carrier fluid passage. More preferably,the bracing wall 82 extends to the two ends of the sealing wall 80. Thebracing wall 82 provides additional support to the sealing wall 80 inthe direction of the force exerted by the carrier fluid. Flexing of thesealing wall 80 is therefore minimized and a the tight seal between thesealing member 64 and the carrier fluid passage 46 is maintained.Preferably, the bracing wall 82 also defines the surface 57. Thisarrangement is preferred because it further reduces the number of partsof the assembly 10.

As mentioned above, the valve 20 can be conveniently operated with onehand while the assembly 10, container 12, and hose can be controlledwith the other hand thereby providing a safe spray operation. Theassembly 10 also preferably includes child-proofing features. As shownin FIGS. 2 and 3, a tab 92 extends from the connection portion 18 andengages an indentation 90 formed on the valve cap 21. When the valve 20is in the closed position (FIG. 2), the tab 92 engages the indentation90 and secures the valve in the closed position. Therefore, to open thevalve 20, the operator must simultaneously pull back the tab 92 androtate the valve 20. This requires a level of strength and dexteritythat is typically not possessed by children.

The illustrated assembly 10 described above is particularly adapted tobe manufactured by injection molding. Because the assembly 10 willtypically be discarded after the chemical in the container 12 isexhausted, the costs of manufacturing the assembly 10 may be low.Injection molding is a particularly low cost method of making parts outof plastic-type materials. Those of ordinary skill in the art willrecognize that the sprayer head 14, the container connection portion 16,the supply fluid connection portion 18, the sealing member 64 and therotatable control valve 20 can all be formed using injection molding.

Another advantage of the present invention is that the valve 20 definesthe metering orifice 74 and the mouth 75. As mentioned above, thediameter of the metering orifice 74 may determine the dilution ratio ofthe sprayer assembly 10. Accordingly, to achieve a precise dilutionratio, tight tolerances may be used in the metering orifice 74 and themouth 75. However, in prior art plastic sprayers, the sprayer headtypically defines the metering orifice and mouth. Because the sprayerhead is a relatively large part that is typically formed in a relativelylarge mold, thermal expansion in the mold makes it difficult to obtaintight tolerances in the metering orifice and mouth.

In comparison, the valve 20 is a much smaller part. Accordingly, thereis less thermal expansion in the mold for the valve 20 as compared tothe mold for the sprayer head 14. Accordingly, it is easier to achievetight tolerances in the valve 20 as compared to the sprayer head 14.Therefore, because the valve 20 of the present invention defines themetering orifice 74 and the mouth 75, it is easier to achieve tighttolerances in the orifice 74 and the mouth 75. Furthermore, because theorifice 74 and the mouth 75 are located in the valve 20, the dilutionratio of the sprayer head assembly 10 can be changed by simply changingthe valve 20. This provides another important advantage.

To further reduce the cost of a aspirator-type sprayer, it is beneficialto use a minimum number of parts. The illustrated assembly 10 preferablyincludes only three main parts: the head 14, the control valve 20, andthe sealing member 64. This represents a great improvement over sprayersthat include a plurality of valves, multiple O-rings and multiplesealing members. Furthermore, the illustrated assembly 10 is easilyassembled. The two main assembling steps are (i) attaching the sealingmember 64 to the valve 20 and (ii) snap-fitting the valve 20 into thevalve chamber 22.

Because of safety concerns, it is generally highly desirable that anaspiration-type sprayer not leak. One of ordinary skill in the art willappreciate that the illustrated assembly 10 described above meets thisrequirement. In particular, the arrangement of the sealing member 64 onthe valve 20 adequately prevents chemicals from leaking.

FIGS. 13A-20 illustrate various portions of a modified embodiment of asprayer head 100. As will be explained below, in this embodiment, thesprayer head 100 may include a housing with connection portions 16, 18(see FIGS. 17 and 18) as described above.

With reference to FIGS. 13A, 17 and 19, the vent passage, channel, oropening 52 may open into a channel 102 formed on the inner bore 22. Thechannel 102 may extend from a portion of the inner bore 22 that includesthe vent passage 52 to an exterior portion 99 of the housing 14. Agroove 104 may be defined within the channel 102 by a depression below afloor 101 of the channel 102. The groove 104 may extend from theexterior portion 99 of the housing 14 to a location in the channel 102adjacent the vent passage 52. In one embodiment, as illustrated in FIGS.13A-20, the groove 104 may terminate before intersecting with the ventpassage 52. It is contemplated, however, that the groove 104, in otherembodiments, may extend to intersect with the vent passage 52.

As shown in FIG. 20, a seal pad 110, the groove 104, and the channel 102may cooperate to extend to an exterior of the housing to form an openingin the housing 14. “Seal pad” as used herein is a broad term and is usedin its ordinary sense and includes without limitation a sealing memberincluding a surface that may seal a portion of the vent passage 52. Inone embodiment, the seal pad 110 may be an elongated piece that isconfigured to have a surface that may seal the passage 52. The seal pad110 may also have a securing flange 109 on a portion of the seal pad 110that extends from the exterior portion 99 of the housing 14. Thesecuring flange 109 may secure the seal pad 110 in place by engaging theexterior portion 99 of the housing 14.

With reference to FIGS. 13A, 14A, 15A-C and 16, the seal pad 110 may beconfigured to be positioned in the channel 102. The seal pad 110, as inthe illustrated embodiment, may include an engagement portion 112 thatis configured to fit over and to engage the vent passage 52. As shown,the engagement portion 112 may be defined by a spherical surface,although the engagement portion 112 may assume other shapes. Forexample, the engagement portion 112 may be conical, ellipsoidal,tetrahedral, frustum, irregular, etc. In one embodiment, the engagementportion 112 may be an annular raised protrusion.

In some embodiments, it may be advantageous for the engagement portion112 to be defined by a spherical surface. The spherical surface may beconfigured to accommodate variable tolerances and changes intemperatures. For example, the spherical surface may permit varioustolerances of the vent passage 52. Additionally, the spherical surfacemay accommodate variations in the size of the vent passage 52 due totemperature or other operating conditions. The spherical surface permitsa perimeter to be engaged by the vent passage 52, and changes in thesize of the vent passage 52 may change the location of the engagingperimeter without affecting the operation of the engagement portion 112.The spherical surface may also be advantageous for ease of manufactureand versatility.

The engagement portion 112 is preferably positioned on a flange 114. Theflange 114 may be a portion of one end of the seal pad 110 that ismoveable about a pivot 115. The pivot 115 may be biased in a directionthat causes the flange 114 to move away from the vent passage 52 whenthe seal pad 110 is placed within the channel 102, as illustrated inFIGS. 15A-C. To permit the flange 114 to be moveable about the pivot115, the seal pad 110 may be made of a flexible plastic, or other memoryshape materials, that may permit temporary deformation of the material.Memory shape materials are materials that are pseudo-elastic and willsubstantially retain a preferred orientation following deformation.

The vent passage 52 preferably has a mouth 113 that is defined by theintersection of the vent passage 52 and the channel 102. The mouth 113may be configured to accommodate the engagement portion 112 and may havethe same shape as the engagement portion 112. The engagement portion 112may be configured to engage the mouth 113, wherein a perimeter of theengagement portion 112 preferably contacts the mouth 113, preventingcommunication between channel 102 and the vent passage 52. Accordingly,the engagement portion 112 may operate to seal the vent passage 52 byengaging the mouth 113, thereby preventing chemical from leaking fromthe container 12 and preventing air from entering into the container 12.In some embodiments, the engagement portion 112 may be configured toextend into the mouth 113 and the vent passage 52, while in otherembodiments, the engagement portion 112 may substantially cover themouth 113 and vent passage 52.

The valve 20 preferably includes a recess 116 formed on the outer wall54 of the valve 20. The recess 116 may be a depression, groove, notch,indentation, etc. in the outer wall 54 of the valve 20 that may providean elevated space 117 (FIG. 14B) above the channel 102. When the recess116 is aligned with the channel 102, the flange 114 of the seal pad 110may assume its preferred, elevated orientation, and the engagementportion 112 on the flange 114 may disengage the mouth 113 and permitcommunication between the channel 102 and the vent passage 52. When therecess 116 is not aligned with the channel 102, the flange 114 of theseal pad 110 is pressed toward the vent passage 52 by the outer wall 54.In this configuration, the engagement portion 112 engages the mouth 113and prevents communication between the channel 102 and the vent passage52.

In an open position (see FIG. 13B), the engagement portion 112preferably permits communication between the channel 102 and the ventpassage 52. “Open position” as used herein is a broad term and is usedin its ordinary sense and includes without limitation a position inwhich the vent passage 52 communicates with the atmosphere. In oneembodiment, the open position is when the engagement portion 112 ismoved away from the vent passage 52, thereby permitting the vent passage52 to communicate with the atmosphere. As illustrated, in the openposition, the recess 116 is aligned with the channel 102, permitting theengagement portion 112 to move to a position (see arrow 117) in which itdoes not block the vent passage 52. In this position, the vent passage52 freely communicates with channel 102. To facilitate transfer of airfor venting, the groove 104 may permit communication between theatmosphere and the channel 102. Accordingly, when the engagement portion112 is not engaged with the mouth 113, air is free to flow from anexterior portion 99 through the groove 104, into the channel 102, andinto the vent passage 52, as indicated by dotted arrow 119 of FIG. 14B.

In a closed position, the engagement portion 112 may be moved to engagethe mouth 113 of the vent passage 52 and seal the vent passage 52 fromcommunicating with the atmosphere. “Closed position” as used herein is abroad term and is used in its ordinary sense and includes withoutlimitation a position in which the vent passage 52 does not communicatewith the atmosphere. In one embodiment, the outer wall 54 of the valve20 forces the engagement portion 112 over the vent passage 52 therebysealing the vent passage 52 and preventing leakage (see FIGS. 13A and14A).

Although the groove 104 is shown in several figures as extending throughthe center of the channel 102, it is contemplated that several grooves104 may be provided, and the grooves may be offset from the center ofthe channel 102. For example, the seal pad 110 may be supported by thechannel 102 along the middle of the seal pad 110, while the channel 102is configured with two grooves 104 on either side of the middle of theseal pad 110. In other embodiments, it is contemplated that the groove104 or grooves could be formed by the seal pad 110. Other configurationsmay also be used.

Other than the recess 116, the valve 20 may be configured and assembledas described above. The recess 116 may be manufactured as a depressionduring the injection molding process or may be subsequently machined. Toprevent the seal pad 110 from falling out of position, the securingflange 109 may engage the exterior portion 99 of the housing 14. Inother embodiments, retaining structures (not shown) may be formed in thegroove 104, securing flange 109, or channel 102 to secure the seal pad110 in place.

Although this invention has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. Thus, it is intended that the scope of the present inventionherein disclosed should not be limited by the particular disclosedembodiments described above, but should be determined only by a fairreading of the claims that follow.

1. A chemical sprayer comprising a sprayer head assembly and a containerthat defines a cavity for storing a chemical to be a sprayed, saidsprayer head assembly comprising: a chemical passage that is incommunication with said cavity; a carrier fluid passage that is incommunication with a carrier fluid source; a valve chamber that is incommunication with said chemical and carrier fluid passages; a valvemoveably positioned within said valve chamber at least partiallydefining a first passage and a second passage, said first passage isconfigured so as to be in communication with said chemical passage whensaid valve is in an open position, said second passage is configured soas to be in communication with said carrier fluid passage when saidvalve is in said open position, said first and second passages alsoconfigured so as to not be in communication with said chemical andcarrier fluid passages when said valve is in a closed position; saidvalve further comprising one or more sealing portions positioned so asto block both the chemical and the carrier fluid passages when saidvalve is in said closed position; a vent passage that is incommunication with said cavity and has an opening in said valve chamber;and a sealing pad actuated by said valve to seal said vent passage, thesealing pad including a biasing portion positioned in the valve chamber,the biasing portion biasing a portion of the sealing pad away from theopening of the vent passage; wherein the sealing pad extends to anexterior of the chemical sprayer.
 2. The chemical sprayer of claim 1,wherein the valve is moveable with respect to the sealing pad.
 3. Thechemical sprayer of claim 1, wherein the valve includes a recessconfigured to accommodate the sealing pad.
 4. The chemical sprayer ofclaim 1, wherein the sealing pad further comprises a is sphericalportion.
 5. The chemical sprayer of claim 1, further comprising aventing groove.
 6. The chemical sprayer of claim 5, wherein the ventpassage is in communication with the venting groove when the valve is inan open position.
 7. A chemical sprayer head assembly comprising: achemical passage that is in communication with a cavity that isconfigured to contain a chemical; a carrier fluid passage that is incommunication with a carrier fluid source; a valve chamber that is incommunication with said chemical and carrier fluid passages; a valvemoveably positioned within said valve chamber at least partiallydefining a first passage and a second passage, said first passage isconfigured so as to be in communication with said chemical passage whensaid valve is in an open position, said second passage is configured soas to be in communication with said carrier fluid passage when saidvalve is in said open position, said first and second passages alsoconfigured so as to not be in communication with said chemical andcarrier fluid passages when said valve is in a closed position; saidvalve further comprising one or more sealing portions positioned so asto block both the chemical and the carrier fluid passages when saidvalve is in said closed position; a vent passage that is incommunication with said cavity; and a seal actuated by said valve,having a seal surface and a biased portion that biases the seal surfaceaway from the vent passage, the valve being moveable with respect to theseal.
 8. The seal of claim 7, wherein the seal further comprises aspherical portion.
 9. The seal of claim 7, wherein the valve furthercomprises a surface configured to actuate the seal.